Multi-well computerized control of fluid pumping

• US 6,368,068 B1
• Filed: 04/11/2000
• Issued: 04/09/2002
• Est. Priority Date: 09/24/1997
• Status: Expired due to Fees

• Current Assignee: Edward A. Corlew, Henry B. Steen III, John W. Smith
• Original Assignee: Edward A. Corlew, Henry B. Steen III, John W. Smith
• Inventors: Smith, John W., Corlew, Edward A., Steen, Henry B. III
• Primary Examiner(s): TYLER, CHERYL JACKSON
• Application Number:
  US09/546,739
• Time in Patent Office: 728 Days
• Field of Search: 961/56, 961/57, 962/04, 962/14, 417/120, 417/139, 417/141, 417/142, 417/143
• US Class Current: 417/120
• CPC Class Codes: E21B 43/121 Lifting well fluids monitoring of down-hole pump systems E21B47/008
• CPC Class Codes: E21B 43/34 Arrangements for separating materials produced by the well
• CPC Class Codes: E21B 43/40 Separation associated with re-injection of separated materials E21B43/385 takes precedence
• CPC Class Codes: E21B 47/008 Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions
• CPC Class Codes: F04F 1/08 specially adapted for raising liquids from great depths, e.g. in wells
• CPC Class Codes: F04F 1/20 specially adapted for raising liquids from great depths, e.g. in wells

Abstract

A system for controlling one or more borehole pumps includes a receiver/separator tank. The receiver/separator tank includes a body having a sealable top cap, an electronics panel, a separator housing, a separator cap that divides the electronics panel from the separator housing, and an inlet base at a second end of the body and dimensioned to maintain entry pipes in appropriate positions. The tank further includes a fluid outlet pipe; a gas pipe; a safety line; a supply line; an exhaust line; a propellant line; a fluid return line; and a spiral diffuser. The spiral diffuser is connected to the fluid return line to disperse fluid received through the return line at an angle to separate gas contained in the fluid. Pressure from the fluid causes the spiral diffuser to spin within the separator housing, and thus, separating gas contained within the fluid from the fluid.

Claims

1. A receiver/separator tank for the separation of fluid and gas having:

a body, said body having a first end and a second end and having

a sealable top cap,

an electronics panel,

a separator housing,

a separator cap, said separator cap dividing said electronics panel from said separator housing,

inlet base, said inlet base being at a said second end and dimensioned to maintain entry pipes in appropriate positions,

a fluid outlet pipe, said fluid outlet pipe being proximate said inlet base,

a gas pipe extending into said housing proximate said receiver/separator cap,

a safety line, said safety line extending into said housing proximate said receiver/separator cap,

a supply line, said supply line extending through said housing to a 3-way control valve to enable said supply line to feed propellant into said housing or exhaust said housing;

an exhaust line, said exhaust line extending from said 3-way control valve to said tanks'"'"' exterior;

a propellant line, said propellant line extending from said 3-way control valve to a propellant pump;

a fluid return line, said fluid return line extending into said housing proximate said receiver/separator cap;

a spiral diffuser, said spiral diffuser being connected to said fluid return line and dispersing fluid received through the return line at an angle to separate gas contained in said fluid,

whereby pressure from said fluid causes said spiral diffuser to spin within said separator housing thereby separating gas contained within said fluid from said fluid.

2. The receiver/separator tank of claim 1 wherein said separator housing further comprises a lower fluid sensor, said lower fluid sensor providing data to a monitoring system to indicate the end of a pumping cycle.

3. The receiver/separator tank of claim 1 wherein said separator house further comprises an upper fluid sensor, said upper fluid sensor providing data to a monitoring system to indicate the beginning of a pumping cycle.

4. The tank of claim 1 wherein said 3-way control valve has a pair of inlets, a moveable interior body having a pair of channels, and an outlet, wherein said moveable interior aligns one of said pair of channels with one of said pair of inlets and said outlet.

5. A receiver/separator tank for the separation of fluid and gas having:

a body, said body having a first end and a second end and having

a sealable top cap,

an electronics panel,

a separator housing,

a separator cap, said separator cap dividing said electronics panel from said separator housing,

inlet base, said inlet base being at a said second end and dimensioned to maintain entry pipes in appropriate positions,

a fluid outlet pipe, said fluid outlet pipe being proximate said inlet base,

a gas pipe extending into said housing proximate said receiver/separator cap, said gas pipe having a fluid baffle,

a safety line, said safety line extending into said housing proximate said receiver/separator cap, said safety line having a pressure relief valve proximate said base,

a supply line, said supply line extending through said housing to a 3-way control valve to enable said supply line to feed propellant into said housing or exhaust said housing;

an exhaust line, said exhaust line extending from said 3-way control valve to said tanks'"'"' exterior;

a propellant line, said propellant line extending from said 3-way control valve to a propellant pump;

a fluid return line, said fluid return line extending into said housing proximate said receiver/separator cap;

a spiral diffuser, said spiral diffuser being connected to said fluid return line and dispersing fluid received through the return line at an angle to separate gas contained in said fluid said fluid;

a lower fluid sensor, said lower fluid sensor providing data to a monitoring system to indicate the end of a pumping cycle,

an upper fluid sensor, said upper fluid sensor providing data to a monitoring system to indicate the beginning of a pumping cycle

whereby pressure from said fluid causes said spiral diffuser to spin within said separator housing thereby separating gas contained within said fluid from said fluid.

6. A method of separating gas from a fluid using a receiver/separator tank having:

a body, said body having a first end and a second end and having

a sealable top cap,

an electronics panel,

a separator housing,

a separator cap, said separator cap dividing said electronics panel from said separator housing,

inlet base, said inlet base being at a said second end and dimensioned to maintain entry pipes in appropriate positions,

a fluid outlet pipe, said fluid outlet pipe being proximate said inlet base,

a gas pipe extending into said housing proximate said receiver/separator cap, said gas pipe having a fluid baffle,

a safety line, said safety line extending into said housing proximate said receiver/separator cap, said safety line having a pressure relief valve proximate said base,

a supply line, said supply line extending through said housing to a 3-way control valve to enable said supply line to feed propellant into said housing or exhaust said housing;

an exhaust line, said exhaust line extending from said 3-way control valve to said tanks'"'"' exterior;

a propellant line, said propellant line extending from said 3-way control valve to a propellant pump;

a fluid return line, said fluid return line extending into said housing proximate said receiver/separator cap;

a spiral diffuser, said spiral diffuser being connected to said fluid return line and dispersing fluid received through the return line at an angle to separate gas contained in said fluid said fluid;

a lower fluid sensor, said lower fluid sensor providing data to a monitoring system to indicate the end of a pumping cycle,

an upper fluid sensor, said upper fluid sensor providing data to a monitoring system to indicate the beginning of a pumping cycle,

comprising the steps of;

a. pumping fluid from a source into said fluid return line;

b. exiting fluid from said fluid return line through said spiral diffuser;

c. rotating said spiral diffuser as said fluid exits said diffuser;

d. collecting said fluid in said inlet base;

e. removing said fluid from said inlet base to a holding tank with said fluid outlet pipe;

f. removing said gas from said separator/receiver through said gas pipe.

7. The method of claim 6 further comprising the step of collecting said gas from said gas pipe in a gas holding taken.

8. The method of pumping fluid from boreholes based on the fluid achieving a predetermined level using a monitoring computer, said monitoring computer being programmed to read and evaluate data obtained from all sensors and controlling said pump and said compressor, comprising the steps of:

a. reading the data received from a plurality of sensors;

b. activating and deactivating a pump;

c. activating and deactivating a compressor;

d. controlling activation time of said pump and said compressor based on signals received from said sensors indicating a sufficient fluid level has been reached within said borehole,

e. activating a secondary program if sensors have not indicated, within a preset period of time, that said fluid level is sufficient for pumping;

g. in said computer, storing and evaluating data received from said sensors,

h. activating a notification system if data is not received from said sensors.

9. The method of claim 8, wherein fluid is pumped from said borehole prior to the fluid level in the borehole becoming equal to the pressure exerted by the incoming fluid.

10. The method of claim 8, wherein said monitoring computer is programmed to operate in a monitor mode, a pumping mode and a recovery mode and wherein, in said monitor mode, the system waits for an initiator, in the form of one or more sensor derived variable inputs, to indicate that a volume of fluid is present in the pumping system to permit efficient pumping to the surface, and during said monitor mode, determining the passage of an established required time between activations of said pump mode and activating said pump mode when a time period has been exceeded.

11. The method of claim 9, wherein the time periods between pumping is stored in a database of said computer, and the establishment of said required time is adaptively modified based on prior pump mode cycles, said time period being adaptively modified by sensing the number of times pump cycles occur without fluid being indicated by a lower fluid level sensor adaptively lengthening the time between pumping cycles when the times pump cycles occur without fluid being indicated by a lower fluid level sensor, exceeds a set value.